Hemocompatible coated polymer and related one-step methods

Abstract

A polymer with a hemocompatible film or coating is manufactured by a one-step method comprising polymerizing monomer droplets comprising at least one crosslinking agent to form a polymer and simultaneously coating the resulting polymer using at least one dispersing agent to thereby form a hemocompatible coated polymer.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a polymer with a hemocompatible coating comprising at least one crosslinking agent for making the polymer and at least one dispersing agent whereby the dispersing agent forms a hemocompatible surface coating on the polymer. More specifically, the present invention relates to a hemocompatible coated polymer manufactured by a method comprising simultaneously polymerizing and coating with at least one crosslinking agent for making the polymer and using at least one dispersing agent to form a hemocompatible coated polymer.

2. Description of Related Art

It has been known and practiced in the art of suspension polymerization to manufacture polymers with a hemocompatible coating using a two-step process. In the first step of the two-step process, polymeric beads are manufactured by polymerizing monomer droplets using suspension polymerization. In the second step of the process, a hemocompatibilizing film is applied onto the exterior surface of the polymer to provide the hemocompatible coating. Unlike the prior art, the polymers of the present invention are manufactured using a one step process which utilizes at least one dispersing agent to form a hemocompatible surface coating on the polymer.

SUMMARY OF THE INVENTION

The present invention relates to a polymer with a hemocompatible coating comprising at least one crosslinking agent for making the polymer and at least one dispersing agent whereby the dispersing agent forms a hemocompatible surface on the polymer. In one embodiment, the dispersing agent comprises a biocompatibilizing polymer.

In another embodiment, the biocompatibilizing polymer comprises poly(N-vinylpyrrolidinone). In still another embodiment, the biocompatibilizing polymer is selected from a group consisting of poly(hydroxyethyl methacrylate), poly(hydroxyethyl acrylate), poly(dimethylaminoethyl methacrylate), salts of poly(acrylic acid), salts of poly(methacrylic acid), poly(diethylaminoethyl methacrylate), poly(hydroxypropyl methacrylate), poly(hydroxypropyl acrylate), poly(N-vinylpyrrolidinone), poly(vinyl alcohol) and mixtures thereof. In another embodiment, the salts may be sodium and potassium salts and in still another embodiment, the salts are water-soluble salts.

In yet another embodiment, the dispersing agent is selected from a group consisting of hydroxyethyl cellulose, hydroxypopyl cellulose, poly(hydroxyethyl methacrylate), poly(hydroxyethyl acrylate), poly(hydroxypropyl methacrylate), poly(hydroxypropyl acrylate), poly(dimethylaminoethyl methacrylate), poly(dimethylaminoethyl acrylate), poly(diethylaminoethyl methacrylate), poly(diethylaminoethyl acrylate), poly(vinyl alcohol), salts of poly(methacrylic acid), and salts of poly(acrylic acid) and mixtures thereof.

In still another embodiment, the crosslinking agent is selected from a group consisting of divinylbenzene, trivinylbenzene, divinylnaphthalene, trivinylcyclohexane, divinylsulfone, trimethylolpropane trimethacrylate, trimethylolpropane dimethacrylate, trimethylolpropane triacrylate, trimethylolpropane diacrylate, pentaerythrital tetra-, tri-, and dimethacrylates, pentaerythritol tetra-, tri- and diacrylates, dipentaerythritol tetra, tri-, and dimethacrylates, dipentaerythritol tetra-, tri-, and diacrylates, divinylformamide, and mixtures thereof.

In still yet another embodiment, the crosslinking agent comprises divinylbenzene. In a further embodiment, the crosslinking agent comprises trivinylcylohexane. In yet a further embodiment, the crosslinking agent comprises trivinylbenzene.

In still a further embodiment, the crosslinking agent comprises copolymers of divinylbenzene with comonomers being selected from a group consisting of styrene, ethylstyrene, acrylonitrile, butyl methacrylate, octyl methacrylate, butyl acrylate, octyl acrylate, cetyl methacrylate, cetyl acrylate, ethyl methacrylate, ethyl acrylate, vinyltoluene, vinylnaphthalene, vinylbenzyl alcohol, vinylformamide, methyl methacrylate, methyl acrylate and mixtures thereof.

In still yet a further embodiment, the polymer with the hemocompatible surface is a porous polymer. In another further embodiment, the polymer with the hemocompatible surface is an ion exchange polymer. In a further embodiment, the polymer is an affinity polymer. In yet another further embodiment, the biocompatibilizing polymer becomes grafted to the surface of the polymer to provide a polymer with the hemocompatible surface. For purposes of this invention, the term “grafting” is defined as chemically bonded with potential entanglement such that the dispersing agent is physically restricted from leaving the surface of the polymer.

In another embodiment, the present invention relates to a polymer manufactured by a process comprising: simultaneously polymerizing and coating with at least one crosslinking agent for making the polymer and using at least one dispersing agent to form a hemocompatible coated polymer.

For purposes of this invention, the term “hemocompatibility” is defined as a condition whereby a material, when placed in contact with whole blood and blood components or physiological fluids, results in clinically acceptable physiological changes. In another embodiment, the dispersing agent is a biocompatibilizing polymer. A “biocompatibilizing polymer” is defined as a polymer, which forms a surface over a non-biocompatible material, making the polymeric system compatible with physiological fluids and tissues. The term “crosslinking agent” is defined as a linking agent such as a polyfunctional monomer that links two or more polymer chains or segments of the same polymer chain together. The term “dispersing agent” is defined as a substance that imparts a stabilizing effect upon a finely divided array of immiscible particles suspended in a fluidizing medium. The immiscible particles can be a solid, liquid or gas and the fluidizing medium can be a liquid or a gas.

In another embodiment, the crosslinking agent is polymerized with at least one vinyl monomer. In a further embodiment, the dispersing agent forms a hemocompatible coating on a surface of the polymer. In yet a further embodiment, the coating of the polymer is equivalent to the surface of the polymer.

In another embodiment, the dispersing agent comprises a biocompatibilizing polymer. In still another embodiment, the biocompatibilizing polymer is poly(N-vinylpyrrolidinone). In another embodiment, the biocompatibilizing polymer is poly(vinyl alcohol). In yet another embodiment, the biocompatibilizing polymer is selected from a group consisting of poly(hydroxyethyl methacrylate), poly(hydroxyethyl acrylate), poly(dimethylaminoethyl methacrylate), salts of poly(acrylic acid), salts of poly(methacrylic acid), poly(diethylaminoethyl methacrylate), poly(hydroxypropyl methacrylate), poly(hydroxypropyl acrylate), poly(N-vinylpyrrolidinone), poly(vinyl alcohol) and mixtures thereof. For purposes of this invention, any biocompatibilizing polymer that can function as a dispersant can be used in accordance with this invention.

In a further embodiment, the dispersing agent is selected from a group consisting of hydroxyethyl cellulose, hydroxypopyl cellulose, poly(hydroxyethyl methacrylate), poly(hydroxyethyl acrylate), poly(hydroxypropyl methacrylate), poly(hydroxypropyl acrylate), poly(dimethylaminoethyl methacrylate), poly(dimethylaminoethyl acrylate), poly(diethylaminoethyl methacrylate), poly(diethylaminoethyl acrylate), poly(vinyl alcohol), salts of poly (methacrylic acid), and salts of poly(acrylic acid) and mixtures thereof.

In still a further embodiment, the crosslinking agent is selected from a group consisting of divinylbenzene, trivinylbenzene, divinylnaphthalene, trivinylcyclohexane, divinylsulfone, trimethylolpropane trimethacrylate, trimethylolpropane dimethacrylate, trimethylolpropane triacrylate, trimethylolpropane diacrylate, pentaerythrital tetra-, tri-, and dimethacrylates, pentaerythritol tetra-, tri- and diacrylates, dipentaerythritol tetra, tri-, and dimethacrylates, dipentaerythritol tetra-, tri-, and diacrylates, divinylformamide and mixtures thereof. In yet a further embodiment, the crosslinking agent comprises divinylbenzene. In still a further embodiment, the crosslinking agent comprises trivinylbenzene. In still another further embodiment, the crosslinking agent comprises divinylnaphthalene. In yet another further embodiment, the crosslinking agent comprises trivinylcylohexane.

In still yet a further embodiment, the crosslinking agent comprises copolymers of divinylbenzene with comonomers selected from a group consisting of styrene, ethylstyrene, acrylonitrile, butyl methacrylate, octyl methacrylate, butyl acrylate, octyl acrylate, cetyl methacrylate, cetyl acrylate, ethyl methacrylate, ethyl acrylate, vinyltoluene, vinylnaphthalene, vinylbenzyl alcohol, vinylformamide and mixtures thereof.

In still a further embodiment, the polymer is processed in non-pyrogenic water. For purposes of this invention, “non-pyrogenic” shall be defined by U.S.P. 25, Monograph (151) Pyrogenic Test, U.S. Pharmacopeia National Formulary.

In still yet another embodiment, the polymer of the present invention is prepared by suspension polymerization. For purposes of the invention, suspension polymerization is defined as the polymerization of monomer droplets dispersed in an immiscible liquid. Based upon an Elemental Analysis of the Polymer's Surface by X-Ray Photoelectron Spectroscopy (XPS), the dispersing agent becomes chemically grafting onto the surface of the polymer as the monomer droplets are transformed into polymeric beads. Polymers coated with poly(N-vinylpyrrolidinone) have been found to be biocompatible and hemocompatible. The hemocompatible polymers of the present invention pass the Lee White clotting tests and the tests for the hemolysis of red blood cells.

In another embodiment, the polymer of the present invention is a porous polymer. The term “porous polymer” is defined as a polymer particle having an internal pore structure with a porosity resulting from voids or holes throughout the polymer matrix. In still another embodiment, the polymer is an ion exchange resin or polymer. An ion exchange resin or polymer is a resin or polymer carrying ionogenic groups that are capable of exchanging ions or of sequestering ions. The ion exchange polymers of the present invention are beneficial when used with blood for removing and isolating varying ions and ionogenic molecules.

In still yet another embodiment, the present invention relates to a polymer with a hemocompatibilizing surface coating. In a further embodiment, the coated polymer is manufactured by a one step process comprising: simultaneously coating and polymerizing monomer droplets in a suspension polymerization procedure with at least one dispersing agent having encapsulated the droplets with a hemocompatible coating to thereby form a polymer with a hemocompatible surface-coating grafted onto the surface of the polymer beads.

In another further embodiment, the dispersing agent comprises a biocompatibilizing polymer. In still a further embodiment, the biocompatibilizing polymer is poly(N-vinylpyrrolidinone). In yet a further embodiment, the biocompatibilizing polymer is selected from a group consisting of poly(hydroxyethyl methacrylate), poly(hydroxyethyl acrylate), poly(dimethylaminoethyl methacrylate), salts of poly(acrylic acid), salts of poly(methacrylic acid), poly(diethylaminoethyl methacrylate), poly(hydroxypropyl methacrylate), poly(hydroxypropyl acrylate), poly(N-vinylpyrrolidinone), poly(vinyl alcohol) and mixtures thereof. In still yet a further embodiment, the polymer geometry comprises beads, spheroids, pellets, granules and mixtures thereof.

In a further embodiment, the monomer droplets are selected from a group consisting of divinylbenzene, styrene, ethylstyrene, acrylonitrile, butyl acrylate, butyl methacrylate, vinyltoluene, vinylnaphthalene, octyl methacrylate, octyl acrylate, cetyl methacrylate, cetyl acrylate, ethyl methacrylate, ethyl acrylate, vinylbenzyl alcohol, vinylformamide and mixtures thereof.

In another embodiment, the present invention relates to a method of manufacturing a biocompatible and hemocompatible surface coated polymer. In still another embodiment, the method comprises: polymerizing monomer droplets comprising at least one crosslinking agent and simultaneously coating the resulting polymer beads using at least one dispersing agent to form a biocompatible surface coated polymer. In still another embodiment, the coated polymers are hemocompatible. In yet another embodiment, the polymer is formed using a suspension polymerization procedure. In another embodiment, the polymer is formed using an emulsion polymerization procedure followed by growing the particles with additional monomer feed.

In still another embodiment, the present invention relates to an application of use whereby the hemocompatible surface coated polymers of the present invention are utilized for medical applications. In another embodiment, the hemocompatible polymers of the present invention may be used to isolate and/or remove target substances from blood and physiological fluids and for specific treatments. In a further embodiment, the hemocompatible polymers of the present invention may be used in preserving organs. In yet another embodiment, the present invention relates to an apparatus for isolating blood components and for purifying blood using the hemocompatible surface coated polymers of the present invention. In one embodiment, the apparatus comprises a cartridge containing the hemocompatible polymers of the present invention.

In yet a further embodiment, the present invention relates to a polymer with a hemocompatible surface coating, the polymer being manufactured by a method comprising: polymerizing monomer droplets comprising at least one crosslinking agent to form a polymer and developing a surface coating on the polymer by using at least one dispersing agent carrying hydroxyl groups followed by a reaction of hydroxyl groups with a vinyl monomer or polymer to thereby form the hemocompatible surface coating on the polymer.

In still yet a further embodiment, the present invention also relates to a method of manufacturing a hemocompatible surface coated polymer using a one step process, the method comprising: polymerizing monomer droplets comprising at least one crosslinking agent to form a polymer and developing a surface coating on the polymer by using at least one dispersing agent carrying hydroxyl groups followed by a reaction of hydroxyl groups with a vinyl monomer or polymer to thereby form the hemocompatible surface coating on the polymer.

In another embodiment, the present invention relates to a polymer having a hemocompatible-coated surface, the polymer being manufactured by a two-step process comprising: polymerizing monomer droplets comprising at least one crosslinking agent and at least one dispersing agent to form a polymer; and coating the surface of the polymer by crosslinking a monovinyl monomer and a polyfunctional monomer mixture over the surface of the polymer bead to thereby form the hemocompatible coating on the surface of the polymer.

In a further embodiment, the present invention relates to a method comprising: polymerizing monomer droplets comprising at least one crosslinking agent and at least one dispersing agent to form a polymer; and coating the surface of the polymer by crosslinking a monovinyl monomer and a polyfunctional monomer mixture over the surface of the polymer bead to thereby form the hemocompatible coating on the surface of the polymer.

In another embodiment, the present invention relates to a hemocompatible system comprising an organic phase and an aqueous phase, wherein the organic phase composed of the polymerizable monomers and the porogen are dispersed into a slurry of droplets by agitation throughout the aqueous phase which is formulated to effect the stability of the droplets by the water-miscible dispersant and to quench polymer growth in the aqueous phase by carrying a water-soluble free radical inhibitor.

DETAILED DESCRIPTION OF THE INVENTION

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various forms. The figures are not necessary to scale, some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.

The specific example below will enable the invention to be better understood. However, they are given merely by way of guidance and do not imply any limitation.

EXAMPLE 1

The first polymer synthesis was targeted at an aqueous to organic volume ratio of 1.0. Table 1 below illustrates the targeted dispersion mixture designed for Example 1 using a fifty (50) liter reaction.

TABLE 1

Dispersion Mixture Desires for 50 Liters


Aqueous/Organic Volume Ratio     1.0
Volume of Organic Phase, ml      25,000.0
Volume of Aqueous Phase, ml      25,000.0
Density of Organic Phase, g/ml   0.83490
Weight of Organic Phase, g       20,872.5
Density of Aqueous Phase, g/ml   1.005
Weight of Aqueous Phase, g       25,125.0
Polymerizable Monomers, DVB plus EVB, g 8766.45
Total Volume of Organic & Aqueous Phases, ml 50,000.0
Total Weight of Organic & Aqueous Phases, g 45,997.5

The procedure for the polymerization in Example 1 is initiated by the preparation of an aqueous phase and an organic phase. Table 2 and 3 below illustrate the components of the aqueous phase composition for the polymer synthesis by weight percent (%) and by quantity of the components in grams (g), respectively.

TABLE 2

Aqueous Phase Composition


Ultrapure Water, wt. %           98.089
Water from Aqueous 45% Solution of 0.611
Poly (N-vinylpyrrolidinone), wt. %
Poly(N-vinylpyrrolidinone) Pure, wt. % 0.500
Sodium Carbonate, wt. %          0.500
Sodium Nitrite, wt. %            0.300

Other dispersants, such as poly(vinyl alcohol) have been used as a substitute for the poly(N-vinylpyrrolidinone).

TABLE 3

Aqueous Phase Charges


Ultrapure Water, g               24,644.83
Water from Aqueous 45% Solution of (153.542)
Poly(N-vinylpyrrolidinone), g
Poly(N-vinylpyrrolidinone) Pure, g (125.625)
Aqueous Poly(N-vinylpyrrolidinone) Solution, 279.167
45 wt. %, g
Sodium Carbonate, g              125.625
Sodium Nitrite, g                75.375
Weights in parenthesis are part of other charged materials
Total Weight of Aqueous Phase, g 25,124.997

Table 4 and 5 illustrate the components of the organic phase composition for the polymer synthesis by weight percent (5) and by quantity of the components in grams (g), respectively.

TABLE 4

Organic Phase Composition


Divinylbenzene (DVB), wt. %      26.998
Ethylvinylbenzene (EVB), wt. %   15.0024
Inerts, wt. %                    0.41567
Toluene, wt. %                   27.134
Isooctane, wt. %                 30.450
Benzoyl Peroxide, wt. % of polymerizable monomers 1.03

Other immiscible porogens such as isooctane, cyclohexane and nonane have been substituted, both singularly and in combination with one another, for the mixture of toluene and isooctane.

TABLE 5

Organic Phase Charges


Divinylbenzene, Pure, g          (5635.069)
Ethylvinylbenzene, Pure, g       (3131.381)
Commercial DVB, Dow 63.5%, g     8853.211
Inerts, g                        (86.761)
Toluene, g                       5663.613
Isooctane, g                     6355.676
Weights in parenthesis are part of commercial DVB
Total Weight of Organic Phase, g (excluding BPO) 20,872.50
Benzoyl Peroxide, BPO, Pure, g   90.294
75 weight percent BPO, g         120.393
97 weight oercent BPO, g         93.087

Upon preparation of the aqueous and organic phases, the aqueous phase is introduced into the reactor. The reactor is set at an agitation rate of approximately 86 revolutions per minute. The aqueous phase is then heated to 65 degrees Celsius with agitation and a nitrogen sweep through the headspace in order to displace oxygen from the reactor space. The organic phase is then introduced into the reactor by pouring or pumping the organic phase onto the aqueous phase under agitation at a stirring rate of at least 86 revolutions per minute. The droplet dispersion is then stirred at 86 revolutions per minute for at least fifteen (15) minutes to set the droplet size and allow the droplet slurry to equilibrate as the temperature is raised from about 65 degrees to about 70 degrees Celsius. Once the droplet dispersion is homogenous throughout the reaction volume, the slurry is then heated to about 75 plus or minus 2.0 degrees Celsius and held at that temperature for ten (10) hours.

The slurry is cooled to about 70 degrees Celsius and the stirrer is turned off, and the polymer beads are allowed to collect at the top of the fluid bed. The mother liquor is then removed from the bottom of the reactor via a pump until the bead bed approaches within about one (1) inch from the bottom of the reactor. The mother liquor is discarded.

A sufficient amount of ultrapure water at ambient temperature is added to fluidize the bead bed. The quality of water needed to wash the beads will be approximately one (1) bed volume or about 25 liters of water. Upon adding the water, the stirrer is then restarted and agitated at a stir rate of 106 revolutions per minute for about five (5) minutes. The stirring is stopped and the beads are allowed to collect at the top of the fluid bed.

The liquor is then drained from the bottom of the reactor via a pump until the bead bed approaches within about one (1) inch from the bottom of the reactor. The wash liquor is discarded. The beads are then washed with the ultrapure water for at least five (5) washes or until the bulk fluid is transparent and free of junk polymer (a clear liquor is achieved). The water-wet bead slurry is transferred to a column that is fitted with a solid-liquid separator at the bottom of the column. The separator may be a mesh or screen made from Teflon, nylon, polypropylene, stainless steel, or glass with pore openings in the size from about 100 to about 300 microns.

The porogen mixture is displaced from the beads by a downflow treatment with ten (10) bed volumes of isopropyl alcohol at a flow rate of one (1) bed volume per hour. The isopropyl alcohol is displaced from the beads with water at a downflow treatment with ten (10) bed volumes of ultrapure water (pyrogen and endotoxin free) at a flow rate of one (1) bed volume per hour. The polymer beads are then transferred from the column into plastic containers for transport to the thermal steam-flux cleaner.

EXAMPLE 2

Experiments were performed using the polymer beads manufactured by the polymerization procedures described in Example 1 and the measured results on the polymer products are illustrated in Tables 6-7 set forth below:

TABLE 6
Experimental Program: Input
	Sample		Sample		Sample	Sample	Sample	Sample	Sample
	ID	Sample ID	ID	Sample ID	ID	ID	ID	ID	ID	Sample ID	Sample ID
LDM	02-001	02-004	02-006	02-008	02-010	02-012	02-015	02-016	02-017	02-022	02-025
Organic Phase
Composition
Monomer (DVB & EVB) Wt. %	42.0	42.0	42.0	42.0	40.7	50.0	40.0	40.0	45.0	45.0	45.0
Porogen Wt. %	58.0	58.0	58.0	58.0	59.3	50.0	60.0	60.0	55.0	55.0	55.0
Porogen/Monomer Ratio	1.3810	1.3810	1.3810	1.3810	1.457	1.000	1.500	1.500	1.222	1.222	1.222
Benzoyl Peroxide (BPO)	1.03	1.03	1.03	1.03	1.03	1.03	1.03	1.03	1.03	1.03	1.03
Wt. %
Porogen Composition
Isooctane, Wt. %	52.5	52.5	52.5	52.5	53.5	60.0	99.327	99.327	99.174	99.174	99.174
Toluene, Wt. %	46.769	46.769	46.769	46.769	45.81	38.99	0	0	0	0	0
Inerts, Wt. %	0.731	0.731	0.731	0.731	0.693	1.010	0.6734	0.826	0.826	0.826	0.726
Toluene plus Inerts, Wt. %	47.5	47.5	47.5	47.5	46.5	40.0	—	—	—	—	—
Isooctane/Toluene plus Inerts	1.105	1.105	1.105	1.105	1.1505	1.500	—	—	—	—	—
Ratio
Aquoeus Phase
Composition
Sodium Carbonate, Wt. %	0.500	0.500	0.500	0.500	0.500	0.500	0.500	0.500	0.500	0.500	0.500
Sodium Nitrate, Wt. %	0.300	0.300	0.300	0.300	0.300	0.300	0.300	0.300	0.300	0.300	0.300
Poly(N-Vinylpyrrolidione) Wt. %	0.500	0.500	0.450	0.400	0.400	0.400	0.100	0.400	0.500	0.500	1.000
PVP K 30, 45-55 Kdaltons,	0	0	0	0	0	0	0	0	0	0.250	1.000
Wt. %
PVP K 60, 400-500 Kdaltons,	0.500	0.500	0.450	0.400	0.400	0.400	0.100	0.400	0.500	0.250	0
Wt. %
Poly(Vinyl alcohol), Wt. %	0.01	0.01	0.05	0.100	0.100	0.100	0.400	0.100	0	0	0
Molecular Size, Kdaltons	88.0	88.0	95.0	95.0	95.0	95.0	95.0	95.0	—	—	—
Amount Hydrolyzed, %	85	85	95	95	95	95	95	95	—	—	—
Aqueous/Organic Phase	0.9	0.9	0.9	0.9	0.9	0.9	0.9	0.9	0.9	1.1	1.1
Volume Ratio
	Sample	Sample	Sample	Sample	Sample	Sample	Sample	Sample	Sample	Sample	Sample	Sample
	ID	ID	ID	ID	ID	ID	ID	ID	ID	ID	ID	ID
LDM	02-028	02-029	02-030	02-031	02-032	02-033	02-034	02-036	02-038	02-040	02-042	02-044
Organic Phase
Composition
Monomer (DVB & EVB) Wt. %	45.0	45.0	45.0	45.0	45.0	50.0	55.0	55.0	55.0	55.0	55.0	55.0
Porogen Wt. %	55.0	55.0	55.0	55.0	55.0	50.0	45.0	45.0	45.0	45.0	45.0	45.0
Porogen/Monomer Ratio	1.222	1.222	1.222	1.222	1.222	1.000	0.8182	0.8182	0.8182	0.8182	0.8182	0.8182
Benzoyl Peroxide (BPO)	1.03	1.03	1.03	1.03	1.03	1.03	1.03	1.03	1.03	1.03	1.03	1.03
Wt. %
Porogen Composition
Isooctane, Wt. %	99.274	99.274	99.274	99.274	99.274	99.1122	98.915	98.915	98.915	98.915	98.915	98.915
Toluene, Wt. %	0	0	0	0	0	0	0	0	0	0	0	0
Inerts, Wt. %	0.726	0.726	0.726	0.726	0.726	0.8878	1.085	1.085	1.085	1.085	1.085	1.085
Toluene plus Inerts, Wt. %	—	—	—	—	—	—	—	—	—	—	—	—
Isooctane/Toluene plus Inerts	—	—	—	—	—	—	—	—	—	—	—	—
Ratio
Aqueous Phase
Composition
Sodium Carbonate, Wt. %	0.500	0.500	0.500	0.500	0.500	0.500	0.500	0.500	0.500	0.500	0.500	0.500
Sodium Nitrate, Wt. %	0.300	0.300	0.300	0.300	0.300	0.300	0.300	0.300	0.300	0.300	0.300	0.300
Poly(N-Vinylpyrrolidione) Wt. %	0.700	0.900	1.000	1.000	1.500	1.000	0.500	1.300	1.100	1.000	0.200	0.300
PVP K 30, 45-55 Kdaltons,	0.700	0.900	1.000	1.000	1.500	0.900	0	1.000	1.000	0.800	0	0
Wt. %
PVP K 60, 400-500 Kdaltons,	0	0	0	0	0	0.100	0.500	0.300	0.100	0.200	0.200	0.300
Wt. %
Poly(Vinyl alcohol), Wt. %	0	0	0	0	0	0	0	0	0	0	0	0
Molecular Size, Kdaltons	—	—	—	—	—	—	—	—	—	—	—	—
Amount Hydrolyzed, %	—	—	—	—	—	—	—	—	—	—	—	—
Aqueous/Organic Phase	1.2	1.2	1.145	1.2	1.2	1.1	1.1	1.0	1.0	1.0	1.0	1.0
Volume Ratio
	Sample	Sample	Sample	Sample	Sample	Sample	Sample	Sample	Sample	Sample	Sample	Sample
	ID	ID	ID	ID	ID	ID	ID	ID	ID	ID	ID	ID
LDM	02-047	02-049	02-050	02-052	02-054	02-055	02-059	02-061	02-073	02-074	02-075	02-079
Organic Phase
Composition
Monomer (DVB & EVB) Wt. %	55.0	55.0	55.0	55.0	55.0	55.0	55.0	55.0	55.0	55.0	55.0	55.0
Porogen Wt. %	45.0	45.0	45.0	45.0	45.0	45.0	45.0	45.0	45.0	45.0	45.0	45.0
Porogen/Monomer Ratio	0.8182	0.8182	0.8182	0.8182	0.8182	0.8182	0.8182	0.8182	0.8182	0.8182	0.8182	0.8182
Benzoyl Peroxide (BPO)	1.03	1.03	1.03	1.03	1.03	1.03	1.03	1.03	1.03	1.03	1.03	1.03
Wt. %
Porogen Composition
Isooctane, Wt. %	98.915	98.915	98.915	98.915	98.915	98.915	98.915	98.915	98.915	98.915	98.915	98.915
Toluene, Wt. %	0	0	0	0	0	0	0	0	0	0	0	0
Inerts, Wt. %	1.085	1.085	1.085	1.085	1.085	1.085	1.085	1.085	1.085	1.085	1.085	1.085
Toluene plus Inerts, Wt. %	—	—	—	—	—	—	—	—	—	—	—	—
Isooctane/Toluene plus Inerts	—	—	—	—	—	—	—	—	—	—	—	—
Ratio
Aqueous Phase
Composition
Sodium Carbonate, Wt. %	0.300	0.100	0.500	0.500	0.500	0.500	0.500	0.500	0.500	0.500	0.500	0.500
Sodium Nitrate, Wt. %	0.300	0.100	0.300	0.300	0.300	0.300	0.300	0.300	0.300	0.300	0.300	0.300
Poly(N-Vinylpyrrolidione) Wt. %	0.010	0.010	0	0.05	0	0	0	0	0	0	0	0
PVP K 30, 45-55 Kdaltons,	0.010	0.010	0	0.05	0	0	0	0	0	0	0	0
Wt. %
PVP K 60, 400-500 Kdaltons,	0	0	0	0	0	0	0	0	0	0	0	0
Wt. %
Poly(Vinyl alcohol), Wt. %	0.250	0.400	0	0	0	0	0.300	0.300	0.300	0.300	0.300	0.300
Molecular Size, Kdaltons	95	95	—	—	—	—	170	170	170	170	170	170
Amount Hydrolyzed, %	95	95	—	—	—	—	88	88	88	88	88	88
Natrosol Plus, Wt. %	0	0	0.500	0.300	0.300	0.300	0	0	0	0	0.05	0
Aqueous/Organic Phase	1.0	1.0	1.0	1.0	1.0	1.0	1.0	1.0	1.0	1.0	1.0	1.0
Volume Ratio
		Sample	Sample	Sample
		ID	ID	ID
	LDM	02-082	02-083	02-086
	Organic Phase
	Composition
	Monomer (DVB & EVB) Wt. %	55.0	55.0	55.0
	Porogen Wt. %	45.0	45.0	45.0
	Porogen/Monomer Ratio	0.8182	0.8182	0.8182
	Benzoyl Peroxide (BPO)	1.03	1.03	1.03
	Wt. %
	Porogen Composition
	Isooctane, Wt. %	98.915	98.915	98.915
	Toluene, Wt. %	0	0	0
	Inerts, Wt. %	1.085	1.085	1.085
	Toluene plus Inerts, Wt. %	—	—	—
	Isooctane/Toluene plus Inerts	—	—	—
	Ratio
	Aqueous Phase
	Composition
	Sodium Carbonate, Wt. %	0.500	0.500	0.500
	Sodium Nitrate, Wt. %	0.300	0.300	0.300
	Poly(N-Vinylpyrrolidione) Wt. %	0	0	0
	PVP K 30, 45-55 Kdaltons,	0	0	0
	Wt. %
	PVP K 60, 400-500 Kdaltons,	0	0	0
	Wt. %
	Poly(Vinyl alcohol), Wt. %	0.300	0.300	0.300
	Molecular Size, Kdaltons	170	100	170
	Amount Hydrolyzed, %	88	85	88
	Natrosol Plus, Wt. %	0	0	0
	Aqueous/Organic Phase	1.0	1.0	1.0
	Volume Ratio

TABLE 7
Experimental Programs: Responses
	Sample ID	Sample ID	Sample ID	Sample ID	Sample ID	Sample ID	Sample ID	Sample ID	Sample ID	Sample ID
	LDM-02-001	LDM-02-004	LDM-02-006	LDM-02-008	LDM-02-010	LDM-02-017	LDM-02-025	LDM-02-034	LDM-02-036	LDM-02-038
Surface Characteristics
SEM; description (smooth,	nodes,	nodes,	nodes,	nodes,	nodes,	no nodes,	no nodes,	no nodes,	no nodes,	nodes,
nodes present, open or closed pore	closed	closed	closed	closed	closed	open	open	open	open	closed
structure)
Internal Pore Structure
BET Surface Area, S	563.5001	652.7807	615.7039	614.4325	661.4491	519.8904	539.9826	537.1961	558.5673	556.5736
Porosity, Pwt in ml.g − 1	0.921032	1.536987	1.530853	1.724477	1.772158	1.240885	1.389936	1.906947	1.958844	1.875443
Pore modes greater than 100 A	150	250,	200,	450	500	250, 310,	320, 450	380, 490	210, 280	210, 280, 380
Diameter from desorption		400	600	550		430, 550, 750	550, 750,	750, 950	380, 500, 650	500, 650, 910
Isotherm. List each						1200, 1800	1200, 1700			1600
Pore modes range in A greater than 100 A diameter,	100-250	100-500	100-700	100-700	100-600	100-1900	100-1800	100-1600	100-1600	100-1600
desorption Isotherm.
Particle Size Distribution
Unclassified, directly from
reactor
Cytonchrome C Sorption
Static Assessment 500 mg/Liter Conc.
Mg cyto c sorbed/g	15.2	43.35	42.95	63.05	79.7	135.9	155.8	86.6	82.0	72.4
dry polymer at 3 hr contact
% of cyto C removed from	19.23	53.8	51.46	66.22	73.78	82.64	82.49	85.12	85.26	68.78
solution at 3 hr contact
Serum Albumin Sorption
% removed from solution with						6.0		4.1		5.1
a concentration of 35,000 mg/l
of serum albumin
Mg BSA(or HSA) sorbed/g dry polymer						1681.7		313.9		328.1
at 3 hr contact
Coating Assessment
ESCA Measurements for Surface Components
Atom Fraction on surface
C	0.8702	0.8722	0.8917	0.8881	0.8855	0.6476	0.6134	0.8981	0.8682	0.8901
O	0.0784	0.0758	0.0682	0.0729	0.086	0.0795	0.1178	0.0778	0.935	0.0771
N	0.0514	0.052	0.0401	0.039	0.0284	0.0281	none	0.0241	0.0383	0.0328
							detected
	Sample ID	Sample ID	Sample ID	Sample ID	Sample ID	Sample ID	Sample ID	Sample ID	Sample ID
	LDM-02-040	LDM-02-044	LDM-02-054	LDM-02-055A	LDM-02-075	LDM-02-079	LDM-02-082	LDM-02-083	LDM-02-086
Cytonchrome C Sorption
Static Assessment 500 mg/Liter Conc.
Mg cyto c sorbed/g	57.6	61.7	73.9	57.8			61.1
dry polymer at 3 hr contact
% of cyto C removed from	61.4	65.5	79.8	63.6			74.9
solution at 3 hr contact
Serum Albumin Sorption
% removed from solution with a concentration of 35,000 mg/l of	3.1
serum albumin
Mg BSA(or HSA) sorbed/g dry polymer	203.1
at 3 hr contact
Coating Assessment
ESCA Measurements of Surface Components
Atom Fraction on surface
C	0.8586	0.8748	0.8238	0.7924
O	0.0982	0.0897	0.1745	0.2076
N	0.0432	0.0355	none	none
			detected	detected
Surface Characteristics
SEM; description (smooth, nodes present, open or	nodes,	nodes,		nodes,
closed pore structure)	closed	closed		closed
Internal Pore Structure
BET Surface Area, S	549.64	545.38	536.79	525.15	531.47		528.93
Porosity, Pwt in ml.g − 1	1.8356	1.642	1.6567	1.6957	1.5232		1.3708
Pore modes greater than 100 A	300; 400;	250; 310;	200; 300;	300; 400;	200; 300;		250; 300;
Diameter from desorption	500; 650;	450; 620;	400; 500;	600; 750;	420; 550;		400; 500; 600;
Isotherm. List each	850	800; 1200	650; 920	900	750; 900; 1200		750; 900; 1300
Pore modes range in A greater than 100 A diameter, desorption	300-980	200-1300	200-1700	150-1300	100-1300		100-1400
Isotherm.
Particle Size Distribution
Unclassified, directly from
reactor

Numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the attendant claims attached hereto, this invention may be practiced otherwise than as specifically disclosed herein.

Claims

1. A method of manufacturing a biocompatible coat polymer, said method comprising:

polymerizing monomer droplets comprising at least one cross agent to form a polymer and simultaneously coating said resultant polymer using a least one polymeric dispersing agent to thereby form a biocompatible coated polymer.

2. The method of claim 1 wherein said polymer is formed using a suspension polymerization procedure.

3. The method of claim 1 wherein said polymer is formed using emulsion polymerization procedure.

4. The method of claim 1 wherein said dispersing agent comprises a biocompatibilizing polymer.

5. The method of claim 4 wherein said biocompatibilizing polymer is poly(N-vinylpyrrolidinone).

6. The method of claim 4 wherein said biocompatibilizing polymer is poly(vinyl alcohol).

7. The method of claim 4 wherein said biocompatibilizing polymer is selected from a group consisting of poly(hydroxyethyl methacrylate), poly(hydroxyethyl acrylate), poly(dimethylaminoethyl methacrylate), salts of poly(acrylic acid), salts of poly(methacrylic acid), poly(diethylaminoethyl methacrylate), poly(hydroxypropyl methacrylate), poly(hydroxypropyl acrylate), poly(N-vinylpyrrolidinone) poly(vinyl alcohol) and mixtures thereof.

8. The method of claim 4 wherein said biocompatibilizing polymer becomes grafted to a surface of said hemocompatible coated polymer.

9. The method of claim 1 wherein said dispersing agent is selected from a group consisting of hydroxyethyl cellulose, hydroxypopyl cellulose, poly(hydroxyethyl methacrylate), poly(hydroxyethyl acrylate), poly(hydroxypropyl methacrylate), poly(hydroxypropyl acrylate), poly(dimethylaminoethyl methacrylate), poly(dimethylaminoethyl acrylate), poly(diethylaminoethyl methacrylate), poly(diethylaminoethyl acrylate), poly(vinyl alcohol), salts of poly(methacrylic acid), and salts of poly(acrylic acid) and mixtures thereof.

10. The method of claim 1 wherein said crosslinking agent comprises copolymers of divinylbenzene with comonomers being selected from a group consisting of styrene, ethylstyrene, acrylonitrile, butyl methacrylate, octyl methacrylate, butyl acrylate, octyl acrylate, cetyl methacrylate, cetyl acrylate, ethyl methacrylate, ethyl acrylate, vinyltoluene, vinylnaphthalene, vinylbenzyl alcohol, vinylformamide and mixtures thereof.

11. The method of claim 1 wherein said crosslinking agent is hydrophobic prior to coating and said external surface of said polymer is rendered hydrophilic and biocompatible after coating.

12. The method of claim 1 wherein said polymer is processed in non-pyrogenic water.

13. The method of claim 1 wherein said crosslinking agent is polymerized with at least one vinyl monomer.